Optimization of FDM (FFF) 3D Printer parameters for Prototyping of Automotive Bumper

Abstract

The research focuses on the effective utilization of a proper FDM (FFF) 3D Printer, with the right material, speed, layer height, laser power, and other settings to manufacture a prototype of an automotive bumper in optimum cost, quality, and time. The Automotive Product Design and development cycle has been reduced from 2-3 years to 6 months. Most Automotive OEMs, and Tier-1 suppliers have started using 3D Printing for plastic, metal parts especially interior, exterior plastics, BIW, seating systems, mirrors, and some engine parts. The objective of this study is to change layer height and nozzle temperature in FDM FFF 3D printing of Automotive Bumper to analyse the effect on 3D printing time (manufacturing time). Today customers demand new and latest products in terms of car design (interior and exterior). The bumper needs to be lucrative, stylish, and ergonomically designed and must follow safety norms. It is very important to rapidly manufacture a prototype of a newly designed bumper for aesthetic as well as to get a feel and touch on PP/ABS with a combination of different colours.